US20070289976A1 - Cargo container for transporting temperature sensitive items - Google Patents

Abstract

A cargo container includes an outer aluminum shell or housing having side, rear, bottom and top walls and a front opening with a pair of hinged doors. The housing receives a molded box-shaped composite outer shell which receives a molded box-shaped composite inner shell defining a cargo chamber. Corresponding walls of the inner and outer shells and the doors confine insulation cassettes each including vacuum insulation panels forming layers, all protected by plastic sheets and plastic film. Air is circulated by blowers within the chamber through a refrigeration evaporator and electrical heating elements, and a rear portion of the housing encloses operating components including a refrigeration compressor, storage batteries and exhaust fans. A control system senses temperature within the chamber and smoke and humidity outside the container and controls the operation of the compressor, exhaust fans and other components from storage batteries or an external power source.

Description

RELATED APPLICATION
• This application is a continuation-in-part of application Ser. No. 11/147,564, filed Jun. 8, 2005.
BACKGROUND OF THE INVENTION
• In the transporting or shipment of temperature sensitive materials or items such as blood, plasma, vaccines and certain drugs, it is known to use insulated containers which include heating and/or cooling means as disclosed, for example in U.S. Pat. No. 5,483,799 and No. 5,603,220 and in U.S. Pat. No. 5,950,450 and No. 5,943,876 assigned to the assignee of the present invention and the disclosures of which are herein incorporated by reference. When it is desirable to transport or ship a larger volume of temperature sensitive items, it is desirable to provide a cargo container which is adapted to receive a pallet supporting the temperature sensitive items and which also includes cooling and/or heating means for maintaining the temperature sensitive items within a close predetermined temperature range. Such cargo containers are disclosed, for example, in U.S. Pat. No. 5,187,947, No. 6,860,115 and in a publication of applicants entitled AcuTemp™ Thermal Pallet Shipper. A Temperature-Controlled, Pallet-Sized Shipping Container is also disclosed in U.S. patent application No. 2004/0226309, published Nov. 18, 2004, and the disclosure of which is herein incorporated by reference. This published application claims the benefit of provisional application No. 60/447,987 filed Feb. 17, 2003 by four co-inventors including co-inventors of the present invention, and the disclosure of which is herein incorporated by reference.
• In any such cargo container adapted to receive one or more pallets of temperature sensitive items, it is highly desirable for the container to have all walls and the doors with high thermal insulation or R value while minimizing the thickness of the walls in order to maximize the cargo space and minimize heat transfer to and from the container chamber. It is also desirable to provide efficient construction and assembly of the cargo container while providing substantial durability so that the cargo container has an extended service life. It is further desirable for temperature controlled air to be properly circulated within the cargo chamber in order to obtain a uniform temperature throughout the chamber. Preferably, the circulating air passes upwardly through a refrigeration evaporator and electrical heating elements and circulates along the walls of the container for precisely controlling the temperature within the cargo chamber.
• In order for a cargo chamber to hold a narrow predetermined temperature range for an extended period of time, for example, over 72 hours, without an external power supply, it is necessary for the cargo container to carry storage batteries which may operate a refrigeration compressor or an electrical heating element through a control system which senses the temperature within the cargo chamber at predetermined locations. The heating element for the circulating air is sometimes desirable when the cargo container is being transported in a cold temperature zone or by an aircraft flying at a high altitude, and the container is exposed to very cold environmental air.
SUMMARY OF THE INVENTION
• The present invention is directed to an improved cargo container assembly which provides all of the desirable features mentioned above including high thermal insulation with a relatively thin wall construction. The container may also be efficiently produced and provides substantial durability and a high strength/weight ratio so that the container may be conveniently handled by forklift trucks without losing its high thermal insulation against heat transfer into and out of the container chamber which receives the cargo or items to be transported.
• In accordance with one embodiment of the invention, a cargo container generally includes a rigid outer housing which may be a sheet aluminum shell or can having opposite side walls connected by a bottom wall, a rear wall and a removable top wall, and with a front or side opening normally closed by hinged door assemblies. When the top wall of the housing is removed, the housing receives a sub-assembly which includes a box-like molded composite outer shell having a front opening and enclosing a box-like molded composite inner shell also having a front opening. The corresponding side, top, bottom and rear walls of the inner and outer shells confine therebetween flat panel insulation cartridges or cassettes. Each cassette includes two or more layers of vacuum insulation panels which may be separated by a foam insulation sheet and sandwiched between protective plastic sheets, all of which are wrapped within a plastic film.
• A wall of the inner shell supports a refrigeration evaporator, an electrical heating element and circulating fans, all protected by a composite inner wall panel which provides for air circulation within the cargo chamber through the evaporator and heating element. The corresponding wall of the outer shell has a rectangular projection which supports a refrigeration compressor and storage batteries, and a control system senses the temperature within the chamber in different areas to operate the compressor and heating element from the batteries or an external power source in order to maintain a substantial constant preselected temperature within the chamber. A compartment of the housing encloses the compressor, storage batteries and control system which includes a plurality of smoke detectors for detecting smoke in the ambient air, and a plurality of ambient air temperature and humidity sensors, all for controlling the exhaust fans for the cargo container.
• Other features and advantages of the invention will be apparent from the following description, the accompanying drawings and the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
• FIG. 1 is a perspective view of a cargo container constructed in accordance with the invention and with the doors in their closed position;
• FIG. 2 is a perspective view of the cargo container shown inFIG. 1 and with the doors shown in their open positions;
• FIG. 3 is a vertical section through the cargo container, taken generally on the line3-3 ofFIG. 1;
• FIG. 4 is a horizontal section of the container, taken generally on the line4-4 ofFIG. 3;
• FIG. 5 is an exploded perspective view of a shell sub-assembly which is inserted into the outer housing assembly shown inFIG. 1 and which supports operating components;
• FIG. 6 is an exploded perspective view of the shell sub-assembly before being inserted into the outer housing assembly;
• FIG. 7 is an exploded perspective view of the door assemblies shown inFIGS. 1 and 2;
• FIG. 8 is an exploded view of an insulation cartridge or cassette used in the walls of the shell sub-assembly and in the door assembly, as shown inFIGS. 5 and 7;
• FIG. 9 is a cross-section of an assembled insulation cassette shown exploded inFIG. 8;
• FIG. 10 is a fragmentary corner section of the top wall and door assembly of the cargo container, taken generally on the line10-10 ofFIG. 1;
• FIG. 11 is a fragmentary section of the overlapping closed door assemblies, taken generally on the line11-11 ofFIG. 1;
• FIG. 12 is a fragmentary corner section of the shell sub-assembly, taken generally on the line12-12 ofFIG. 6;
• FIG. 13 is a fragmentary section of the shell sub-assembly, taken generally on the line13-13 ofFIG. 6;
• FIG. 14 is a fragmentary section of the shell sub-assembly, taken generally on the line14-14 ofFIG. 6;
• FIG. 15 is a fragmentary section of the shell sub-assembly, taken generally on the line15-15 ofFIG. 6;
• FIG. 16 is a fragmentary corner section of the shell sub-assembly, taken generally on the line16-16 ofFIG. 6;
• FIG. 17 is a rear perspective view of a modified cargo container with the rear wall enclosure and storage batteries removed; and
• FIG. 18 is a block diagram of the electrical components and control system for the cargo container.
DESCRIPTION OF ONE EMBODIMENT
• Referring toFIG. 1, acargo container25 includes anouter housing28 which is formed of sheet aluminum and aluminum corner trim and sometimes referred to as a “can”. Thehousing28 includesopposite side walls32, a removabletop wall34, arear wall enclosure36 and a bottom wall38 (FIG. 3). Thehousing28 is supported by a set of hollow aluminum supports orlegs41 connected by analuminum base plate42, and thespaced legs41 are arranged to allow a two or three way entry under thecargo housing28 with a forklift truck. The transporting of thecontainer25 may be over the road (OTR) by trucks or rail or may be transported as a unit loading device (ULD) by a ship or aircraft. Thehousing28 also supports a pair of swinging door units orassemblies44 and46 (FIGS. 1 & 2) each supported by a set ofhinges47 attached to the housing.
• Referring toFIG. 6, before thetop wall34 of the housing is installed, thehousing28 receives ashell sub-assembly50 which includes a molded composite box-like outer shell54 (FIGS. 5 & 6) and a molded composite box-likeinner shell56, shown exploded inFIG. 5. Each of theshells54 and56 is molded as a one-piece unit, and theouter shell54 includes a resin impregnated fiber reinforcedouter skin62 which forms opposite side walls64 (FIG. 5) integrally connected by atop wall66 and a bottom wall68 (FIG. 5). Theouter shell54 also has an integrally moldedrear wall72, andsupport walls74 project rearwardly from therear wall72 of theouter shell54, and are also formed of fiber reinforced composite plastic material and may be formed integrally with therear wall72 of theouter shell54.
• The molded fiber reinforcedside walls64,rear wall72, projectingsupport74 and thebottom wall68 are also molded with fiber reinforcedpanels82 and83 (FIG. 12) and84 (FIG. 3) which provide substantial additional strength and impact resistance to theouter shell54. Preferably, the fiber reinforced panels82-84 are formed from fiber reinforced core panels produced as disclosed in U.S. Pat. No. 6,740,381, the disclosure of which is herein incorporated by reference. The molding of the compositeouter shell54 may be performed by vacuum assisted resin transfer molding (RTM) so that the resin penetrates the fibrous fabric forming theouter skin62 of theshell54 and also simultaneously penetrates the fibers within the fiber reinforced core panels82-84 having inner skins and integral with theouter skin62.
• As mentioned above, theshell sub-assembly50 also includes a composite box-like inner shell56 (FIG. 5) which is molded in the same manner as theouter shell54 and includes a one-piece fiber reinforced inner skin92 (FIG. 5) which formsopposite side walls94, atop wall96, a rear wall97 (FIGS. 4 & 5) and a bottom wall98 (FIG. 12). All of the walls are integrally connected, and therear wall97 is provided with integrally molded co-planar step portions102 (FIG. 4). Theside walls94 are molded with vertically spaced horizontal reinforcingribs106, and the lower portions of theside walls94 and thebottom wall98 are also molded with fiber reinforcedcore panels108 and110, respectively, which are resin impregnated with theinner skin92 and formed in the same manner as theouter core panels8284. The fiber reinforced core panels have a thickness of about ½ inch, and after the resin hardens, the reinforced panels provide the walls of theouter shell54 and the lower portion of theinner shell56 with substantial rigidity and impact strength, as described in above mentioned U.S. Pat. No. 6,740,381.
• Referring toFIGS. 3 and 5, an aluminum or molded fiber reinforced partition orpanel114 has an open top and open bottom and is attached to therear wall97 of theinner shell56 to define an upwardflow air passage116 adjacent therear wall97. A molded fiber reinforcedflat panel120 having a fiber reinforced core as described above, is attached to thestep portions102 of therear panel97 and cooperates with theside walls94,top wall96 andbottom wall98 of theinner shell56 to define acargo receiving chamber125. The volume of thechamber125 may be on the order of 30 or 45 or 60 or 90 cubic feet, and is sufficiently large to receive a standard size pallet. The composite cold wallflat panel120 is vertically reinforced, for example, by having vertical fibrous webs in the fiber reinforced core to provide thepanel120 with additional strength.
• As shown inFIGS. 5 and 12, a series of laterally spacedchannels130 are molded as part of thebottom wall98 or are attached to thebottom wall98 of theinner shell56 byadhesive132, and thechannels130 support a substantially flat aluminum floor panel orplate135 having a thickness of about ⅛ inch. The floor plate135 (FIGS. 12 & 14) extends from the front opening of theinner shell56 to thecold wall120 to partition the innercargo receiving chamber125 from sub-floor air channels orpassages138. Thesub-floor channels130 extend from the front opening of theinner shell56 to itsrear wall97, to create theair return passages138 underfloor plate135 together with the inner shell floor98 (FIG. 5). These passages connect the return air flow from the bottom front of theinner shell56 to the upward flow air passage116 (FIG. 3) for the evaporator/heater assembly. The sides of thefloor plate135 are provided with upwardly facing tie-down seat channels139 (FIG. 4) for receiving straps or nets extending over the cargo. The forward edge portion of thefloor plate135 has a series of parallel spaced slots142 (FIG. 4) which connect with theair flow passages138. As shown inFIG. 3, the rearward ends of thepassages138 are open and provide for air flow from the passages upwardly into thechamber116 defined by thepanel114.
• Referring toFIGS. 5, 8 and9, a set of flat panel thermal insulation cartridges orcassettes145,146,147 and148 are confined or sandwiched between the walls of theouter shell54 and theinner shell56. As shown inFIGS. 8 and 9, each of the insulation cassettes145-148 includes a plurality of at least two panels orlayers152 each including a plurality ofvacuum insulation panels155. Each of thepanels155 is constructed substantially as disclosed in U.S. Pat. No. 6,623,413 assigned to the assignee of the present invention and the disclosure of which is herein incorporated by reference. As generally disclosed in the patent, each of thepanels155 includes a core of porous material enclosed within a bag of gas impermeable film. After the bag is evacuated, the bag is sealed to form a vacuum insulation panel as generally shown inFIG. 1 of the patent. Each of thelayers152 of vacuum insulation panels has a thickness of about ½ inch, and the layers are separated by aflat sheet158 of plastic or expanded polystyrene foam and having a thickness of about ¼ inch. Thelayers152 ofvacuum insulation panels155 are protected by and sandwiched between twoouter sheets162 of extruded plastic, for example, sold under the trademark “CoruPlast”. All of the assembledlayers152 andsheets158 and162 are wrapped with aflexible film164 of fire retardant plastics material.
• The thermal insulation panel assemblies145-148 are illustrated in the partial section views ofFIGS. 10-16 as a one-piece insulation panel for simplification, but it is to be understood that each of the panels145-148 is constructed substantially as described above in connection withFIGS. 8 and 9. As shown inFIG. 16, a set of fiber reinforcedribs170 are molded as an integral part of theinner shell56 along the top and bottom and function as rigid spacers between the inner and outer shells. As also shown inFIGS. 5, 10 and13-15, the inner fiber reinforcedskin42 of theinner shell56 is molded with an outwardly projectingreturn flange portion172 which extends around the front end of theinner shell56 and has a U-shaped cross-sectional configuration as shown inFIGS. 10 and 13-15. As shown inFIGS. 12 & 16, theinsulation cassettes145 and146 have partial insulation panel extensions which project into the corner spaces between the shells. Additionally, similar insulation extensions project into sections where closed cell PVC expanded foam has been removed to reduce the heat shunts. This facilitates the connection of the insulation cassettes to each other, improving overall insulation coverage and reducing heat leaks. Closed cell PVC expandedfoam174 fills the space between thereturn flange172 and the front edges of the insulation panels145-147 and may be used in other voids within thecontainer25.
• As also shown inFIGS. 10 and 13-15, thereturn front flange172 of theinner shell56 is attached or bonded to the forward end skin portion of theouter shell54 bystrips176 of adhesive. Also shown inFIG. 5, arectangular trim frame180 is molded of a plastics material such as ABS and has an L-shaped cross sectional configuration. Theframe180 defines the front opening for thecargo container chamber125 and is attached or bonded to the fiber reinforced skin of theinner shell56 bystrips184 and186 of adhesive. The front end portions of the skin of theinner shell56 may also be provided with interruptions to form thermal breaks for eliminating heat transfer through the skin.
• Referring toFIG. 7, each of thedoor assemblies44 and46 includes an outer aluminum sheet orpanel196 secured to a rectangulartubular aluminum frame198 to which thehinges47 are secured. The inner surfaces of thedoor assemblies44 and46 are formed bypanels202 and203, respectively, which are vacuum formed of a plastics material such as ABS and include an outwardly projectingperipheral flange204 which is attached to theframe198 of the door assembly by peripherally spaced screws or rivets. Each of thepanels202 and203 is formed with parallel spacedvertical channels206, and a series of expanded foam strips208 are attached to the inner surface of the panel between thechannels206 to provide a flush surface. Each of thepanels202 and203 also encloses aninsulation cassette210 which is constructed substantially the same as the construction of the insulation cassettes145-148 described above in connection withFIGS. 8-9. That is, each of theinsulation cassettes210 includes twolayers212 ofvacuum insulation panels155 and the layers are separated by an expandedpolystyrene foam sheet214. Twopanels216 of expanded polystyrene foam are also located between thecassette210 and thealuminum panel196.
• As shown inFIGS. 7 and 11, the lefthand door assembly46 includes anextension channel220 which is vacuum formed from a sheet of plastics material such as ABS and is attached to the inner vacuum formedpanel202 of the door assembly. As shown inFIG. 11, theextension channel220 overlaps astep portion222 of thepanel203 of the righthand door assembly44. Theextension channel220 is filled by alateral extension224 of theinner layer152 of thevacuum insulation panels155 of the correspondinginsulation cassette210. The cassettes cooperate with thefoam boards216 to provide substantial thermal insulation for thedoor assemblies44 and46. As shown inFIG. 4, the channels of thedoor panels202 form air flow passages extending vertically directly above theslots142 within thealuminum floor panel135. As shown inFIG. 1, areleasable latch mechanism225 connects the door assemblies.
• Referring toFIGS. 3 and 4, thecomposite panel114 between therear wall97 of theinner shell56 and thecold wall panel120, encloses anevaporator assembly230 of a refrigeration system and also encloses an electrical heating coil orelement232. The impellers or fans ofblowers235 operate to pull the air upwardly within thechannel116 and pass theheating element232 and through theevaporator assembly230. Insulation strips236 block air flow outside ofpassage116. The blowers force the cooled or heated air through an opening or space at the top of theportion120 and forwardly along thetop wall96 of theinner shell56 and within thechamber125 to thefront door assemblies44 and46 where the air flows downwardly along the inner surfaces of thedoor panels202 and then through theslots142 within thefloor panel135. The air then flows rearwardly within thepassages138 below the floor panel and back into the bottom opening of theair flow passage116. In this manner, air is continuously circulated around the payload or cargo within thechamber125. In the event the cargo is tight against the inner surfaces of thedoor panels202, thechannels206 provide air flow passages so that the air flow continues to flow downwardly along the door assemblies and into theslots142 within the floor panel. In a preferred embodiment, a low power fan may be used to stir the air in the chamber when themain blowers235 are not operating.
• Referring again toFIGS. 3 and 4, the upper wall of the rectangular rear projection orextension74 molded as an integral part of the compositeouter shell54 supports a motor drivenrefrigeration compressor240 andcondenser242 having ahousing supporting fans244. The compressor and condenser are connected to theevaporator230 by lines (not shown) extending through aligned holes within therear wall72 of theouter shell54, theinsulation cassette148 and therear wall97 of theinner shell56. The bottom wall of theextension74 supportsrechargeable storage batteries250 which provide an output of 12 or 24 volts DC to operate therefrigeration compressor240, theheater element232 and theblower fans235. Tie downstraps252 andbolts253 secure the batteries positively to the bottom wall of theextension74 of theouter shell54.
• As shown inFIG. 3, a set of upper and lowerrectangular air vents256 are provided in the rear compartment orextension36 of theouter housing28 to provide convection ventilation within the housing portion. As shown inFIGS. 1 and 2, a side wall of thehousing extension36 supports an exposed door coveredcontrol panel260 of a controller262 (FIG. 4), and thehousing extension36 also encloses abattery charger264 and a dual voltagepower supply connector266 for the battery charger for receiving an external power supply of 110 volts or 240 volts AC. The control panel also encloses a universal AC voltage (100-240 VAC, 46-63 Hz) battery charger connector and a 12-28 V external DC power connector. Thebattery charger264 is mounted on the side wall of therectangular projection74 and is connected to the universal AC voltage connector. The motor drivencompressor240 is mounted on the upper wall of therectangular projection74 and is connected to the internal and external DC power source through thecontroller262.
• FIG. 17 is a rear view of a modifiedcargo container25′ which is constructed substantially as described above for thecargo container25. In this modification, an elongated fiber reinforced box-like support74′ is attached or bonded to therear wall72 of theouter shell54 and is enclosed by a removablerear panel276. A set of threeexhaust fans244 are supported by theclosure panel276 and are aligned with theupper air vent256 in therear wall enclosure36. Another box-like support280 is also attached or bonded to therear wall72 of theouter shell54 and is also constructed from fiber reinforced composite panels, as disclosed in above-mentioned U.S. Pat. No. 6,740,381. Thesupport280 has an open top and is opened at the rear for receiving and supporting thestorage batteries250. Thesupport74′ and therear wall72 of theouter shell54 also support a plurality of four commerciallyavailable smoke detectors285 each of which is capable of detecting smoke in the ambient air surrounding thecargo container25′ and within therear wall enclosure36. As shown inFIG. 18, thedetectors285 are connected to thecontroller262 along with a plurality of four temperature andrelative humidity sensors290 which are located to sense the ambient air outboard of the cargo container.
• The operation of therefrigeration compressor240, theexhaust fans244, theheating element232 and the internalair circulating blowers235 is controlled from thecontroller262. A set of temperature sensing thermistors272 (FIG. 3) are located in each of the eight corners of thecargo chamber125 and at the front center of thefloor panel135 and are also connected to thecontroller262. A more detailed description of the operation and control of the heating and cooling system is set forth in above mentioned published U.S. patent application No. 2004/0226309, the disclosure of which is incorporated herein by reference.
• The operation of theexhaust fans244 is also controlled by thesmoke detectors285 and the temperature andrelative humidity sensors290 through thecontroller262. That is, in the event any one of thesmoke detectors285 detects smoke, the exhaust fans are shut down until thecontroller262 is manually reset so that there is no air flow through the air vents56 and no air exchange between the cargo container and the ambient air surrounding the container. In the event that the temperature andhumidity sensors290 detect that the ambient temperature surrounding the cargo container is too low or the relative humidity is too high, thecontroller262 will also shut down theexhaust fans244. When the ambient temperature and/or the humidity return to the preselected ranges, thecontroller262 automatically restarts theexhaust fans244. Thus, when the cargo container is used within the cargo area of an aircraft, the control system assures that there is no interference by the cargo container with the aircraft heat and smoke detection system.
• From the drawings and the above description, it is apparent that a cargo container constructed and assembled in accordance with the invention provides desirable features and advantages. For example, the construction of thecargo container25 or25′ with the resin impregnated fiber reinforced walls of theouter shell54 andinner shell56 with the thermal insulation cassettes145-148 confined between the composite walls provides a very desirable high insulation value, for example, an R value of over 50. As a result, temperature sensitive cargo may be maintained at a substantially constant temperature for an extended period of time with minimum energy consumption from thebatteries250 to operate therefrigeration compressor240 or theelectrical heating element232. For example, if a temperature in thecargo chamber125 is selected betweenplus 2° C. and plus 25° C., it is possible to maintain the temperature within plus or minus 1° C. for up to 72 hours without using an external power source. This permits temperature sensitive cargo to be delivered practically anywhere in the world by aircraft while maintaining a substantially constant temperature. Furthermore, the fiber reinforced composite walls of the inner and outer shells and the fiber reinforced core panels within the walls provide substantial impact protection for the vacuum insulatedpanels155 while minimizing the weight of the wall panels. It is also within the scope of the invention to increase the thickness and strength of the fiber reinforced wall panels of the outer shell and eliminate the outer aluminum can orhousing28 so that the outer shell forms the outer housing, thereby reducing the overall weight and production cost of the cargo container.
• Another advantage is provided by the construction and assembly of the thermal insulation cartridges or cassettes145-148 and210 with the joints of thevacuum insulation panels155 on one side of theseparation sheet158 being offset and crossing the joints of thethermal insulation panels155 on the opposite side of thesheet158. As a result, the transfer of heat between the vacuum insulation panels is minimized or substantially eliminated, thereby further increasing the resistance to heat transfer through the wall panels. The circulation of the air within thecargo chamber125 also helps to maintain a substantially constant temperature within the chamber. For example, cold air produced by theevaporator230 is forced forwardly by theblowers235 along thetop wall96 of theinner shell56 and downwardly along the inside surface of the front door assemblies, through theslots142 and then rearwardly within thepassages138 between thefloor channels130 and under thefloor plate135 for return to the lower open end of theevaporator panel114. As mentioned above, thechannels206 within theinner door panels202 assure that the downward flow of air cannot be blocked by cargo items within thechamber125.
• Further advantages are provided by the use of thesmoke detectors285 and the temperature andrelative humidity sensors290 to control the operation of theexhaust fans244. This control system prevents the cargo container from interfering with any smoke detection system in an aircraft transporting the cargo container, and thesensors290 cooperate to maintain the desired range of temperature in thecargo container chamber125.
• While the method of construction and form of cargo container herein described constitute desirable embodiments of the invention, it is to be understood that the invention is not limited to the precise method and form of container described, and that changes may be made therein without departing from the scope and spirit of the invention as defined in the appended claims.

Claims (38)

1. A cargo container assembly adapted for transporting a temperature sensitive cargo supported by a pallet, said assembly comprising a box-like composite outer shell having side, top and bottom walls of resin impregnated fibers and having a front opening and a moveable door assembly for closing said front opening, a box-like composite inner shell within said outer shell and having side, top and bottom walls of resin impregnated fibers and spaced inwardly from the corresponding said walls of said outer shell and defining a cargo receiving chamber, thermal insulation material confined between the corresponding said side, top and bottom walls of said inner and outer shells, and a refrigeration system connected to cool said chamber.

2. A cargo container assembly as defined inclaim 1 wherein said thermal insulation material comprises vacuum insulated panels each including a core of porous material confined within an evacuated sealed bag of flexible gas impermeable film.

3. A cargo container assembly as defined inclaim 2 wherein said vacuum insulated panels are arranged in substantially flat layers each having a plurality of said vacuum insulated panels confined between protective panels, and said layers and said protective panels are surrounded by a flexible film of plastics material to form a vacuum insulated cassette.

4. A cargo container assembly as defined inclaim 3 wherein said vacuum insulated panels in one of said layers have abutting joints crossing abutting joints of said vacuum insulated panels in a second of said layers.

5. A cargo container assembly as defined inclaim 1 wherein at least one of said walls of said outer shell comprises resin impregnated fibrous inner and outer skins bonded to a core of low density cellular material with resin impregnated reinforcing fibers extending through said core and connecting said skins.

6. A cargo container assembly as defined inclaim 1 wherein at least some of said walls of said inner and outer shells comprise resin impregnated fibrous inner and outer skins bonded to a core of low density cellular material having resin impregnated reinforcing fibers extending through said core and connected to said skins.

7. A cargo container assembly as defined inclaim 1 wherein said outer shell includes a rear wall having rearwardly projecting support members, and a refrigeration compressor and a set of storage batteries mounted on said projecting support members.

8. A cargo container assembly as defined inclaim 1 wherein each of said inner shell and said outer shell has integrally connected side, top, bottom and rear walls to form a one-piece unit, insulation cassettes between corresponding said walls, and each of said insulation cassettes including a plurality of vacuum insulated panels each including a core of porous material confined within an evacuated sealed bag of flexible gas impermeable film.

9. A cargo container assembly as defined inclaim 1 wherein said bottom wall of said inner shell includes a plurality of parallel spaced members defining air flow passages therebetween, and a rigid floor panel mounted on said spaced members.

10. A cargo container assembly as defined inclaim 9 wherein said floor panel includes a plurality of laterally spaced openings adjacent said door assembly and providing for air flow through said passages from said cargo receiving chamber.

11. A cargo container assembly as defined inclaim 1 wherein said door assembly comprises a rigid outer door panel, a formed sheet of plastics material connected to said outer door panel and defining a space therebetween, a vacuum insulated panel assembly disposed between said sheet of plastics material and said outer door panel, and said vacuum insulated panel assembly comprising a core of porous material confined within a sealed bag of flexible gas impermeable film.

12. A cargo container assembly as defined inclaim 11 wherein said formed sheet of plastics material comprises a plurality of parallel spaced and generally vertical integral ribs defining air flow passages therebetween.

13. A cargo container assembly as defined inclaim 1 and including a set of reinforcing members disposed between said inner and outer shells to protect said vacuum insulated panel assemblies.

14. A cargo container assembly adapted for transporting a temperature sensitive cargo supported by a pallet, said assembly comprising a box-like outer shell including side, top and bottom walls having a front opening and a moveable door assembly for closing said front opening, a box-like inner shell within said outer shell and including side, top and bottom walls spaced inwardly from the corresponding said walls of said outer shell and defining a cargo receiving chamber, vacuum insulated panel assemblies confined between the corresponding said side, top and bottom walls of said inner and outer shells, at least one of said vacuum insulated panel assemblies including substantially flat parallel insulation layers each having a plurality of vacuum insulated panels, each of said panels including a core of porous material confined within an evacuated sealed bag of flexible gas impermeable film, and a refrigeration system connected to cool said chamber.

15. A cargo container assembly as defined inclaim 14 wherein said layers of vacuum insulated panels are confined between flat protective panels, and said layers and said protective panels are surrounded by a flexible film of plastics material to form a vacuum insulated cassette.

16. A cargo container assembly as defined inclaim 15 wherein said vacuum insulated panels in one said layer have abutting joints crossing abutting joints of said vacuum insulated panels in a second said layer.

17. A cargo container assembly as defined inclaim 14 wherein said walls of said outer shell comprise resin impregnated fibrous inner and outer skins bonded to a core of low density cellular material with resin impregnated reinforcing fibers extending through said core and connecting said skins.

18. A cargo container assembly as defined inclaim 14 wherein at least some said walls of said inner and outer shells comprise resin impregnated fibrous inner and outer skins bonded to a core of low density cellular material having resin impregnated reinforcing fibers extending through said core and connected to said skins.

19. A cargo container assembly as defined inclaim 14 wherein said outer shell includes a rear wall integral with said side wall, top and bottom walls of said outer shell, said rear wall supports projecting support members, and a removable housing member enclosing said support members on said outer shell.

20. A cargo container assembly adapted for transporting a temperature sensitive cargo supported by a pallet, said assembly comprising a box-like outer shell including side, top and bottom walls and having a front opening and a moveable door assembly for closing said front opening, a box-like inner shell within said outer shell and including side, top and bottom walls spaced inwardly from the corresponding said walls of said outer shell and defining a cargo receiving chamber, thermal insulation material confined between the corresponding said side, top and bottom walls of said inner and outer shells, a refrigeration system connected to cool said chamber and including a compressor and at least one exhaust fan, a smoke detection system connected to control said exhaust fan, and said smoke detection system includes at least one smoke detector connected to de-energize said exhaust fan in response to the detection of smoke in the ambient air outside of said cargo container assembly.

21. A cargo container assembly as defined inclaim 20 and including a plurality of said exhaust fans, and all of said fans are connected to be de-energized in response to the detection of smoke by any one of said detectors.

22. A cargo container assembly as defined inclaim 20 and including a plurality of temperature and humidity sensors, and said exhaust fan is connected to be de-energized in response to actuation of any one of said temperature and humidity sensors.

23. A cargo container assembly as defined inclaim 20 wherein said smoke detection system includes a plurality of said smoke detectors.

24. A cargo container assembly as defined inclaim 20 wherein said thermal insulation material comprises vacuum insulated panels each including a core of porous material confined within an evacuated sealed bag of flexible gas impermeable film.

25. A cargo container assembly as defined inclaim 20 wherein said outer shell comprises an outer housing for said cargo container assembly.

26. A cargo container assembly adapted for transporting a temperature sensitive cargo supported by a pallet, said assembly comprising a box-like outer shell including side, top and bottom walls and having a front opening and a moveable door assembly for closing said front opening, a box-like inner shell within said outer shell and including side, top and bottom walls spaced inwardly from the corresponding said walls of said outer shell and defining a cargo receiving chamber, thermal insulation material confined between the corresponding said side, top and bottom walls of said inner and outer shells, a refrigeration system connected to cool said chamber and including a compressor and at least one exhaust fan, at least one sensor for sensing temperature and humidity of the ambient air outside said outer shell, and a control system connected to de-energize said exhaust fan in response to said sensor sensing a predetermined temperature level and/or a humidity level of the ambient air outside of said cargo container assembly.

27. A cargo container assembly as defined inclaim 26 and including a plurality of said exhaust fans and a plurality of sensors, and all of said exhaust fans are de-energized in response to any one of said sensors sensing said predetermined level of temperature and/or humidity.

28. A cargo container assembly as defined inclaim 26 wherein said thermal insulation material comprises vacuum insulated panels each including a core of porous material confined within an evacuated sealed bag of flexible gas impermeable film.

29. A cargo container assembly as defined inclaim 26 wherein said outer shell comprises an outer housing for said cargo container assembly.

30. A method of making a cargo container assembly adapted for transporting a temperature sensitive cargo supported by a pallet, said method comprising the steps of:

forming a box-like composite outer shell including side, top, rear and bottom walls of fiber reinforced plastic and defining a front opening with a moveable door assembly for closing the opening;

forming a box-like composite inner shell including side, top, rear and bottom walls of fiber reinforced plastic and defining a cargo receiving chamber;

inserting the inner shell into the outer shell;

locating thermal insulation material between the corresponding side, top, rear and bottom walls of the inner and outer shells; and

installing a power operated refrigeration system having an evaporator positioned to control air within the inner shell and connected to a motor driven compressor and at least one exhaust fan located outside of the outer shell.

31. A method as defined inclaim 30 and including the steps of:

forming a plurality of vacuum insulated panels to form the thermal insulation material, and forming each of the vacuum insulated panels with a core of porous material confined within an evacuated sealed bag of flexible gas impermeable film.

32. A method as defined inclaim 31 and including the steps of:

positioning a plurality of the vacuum insulated panels in layers between protective sheets, and surrounding the layers of vacuum insulated panels and the protective sheets with a flexible film of plastics material to form a vacuum insulated cassette.

33. A method as defined inclaim 32 and including the step of:

arranging the vacuum insulated panels in one layer with abutting joints crossing abutting joints of the vacuum insulated panels in a parallel second layer.

34. A method as defined inclaim 30 including the step of:

forming the walls of the outer shell with resin impregnated fibrous inner and outer skins bonded to a core of low density cellular material with resin impregnated reinforcing fibers extending through the core and connecting the skins.

35. A method as defined inclaim 30 and including the steps of:

locating at least one smoke detector outside of the outer shell for sensing smoke in the ambient air surrounding the cargo container, and connecting the exhaust fan to shut down in response to smoke detected by the smoke detector.

36. A method as defined inclaim 30 and including the steps of:

locating at least one temperature and humidity sensor outside the outer shell for sensing the temperature and humidity of the ambient air surrounding the cargo container, and connecting the exhaust fan to shut down in response to sensing temperature or humidity of the ambient air outside predetermined ranges.

37. A method of making a cargo container assembly adapted for transporting a temperature sensitive cargo supported by a pallet, said method comprising the steps of:

forming a box-like outer shell including side, top, rear and bottom walls defining a front opening with a moveable door assembly for closing the opening;

forming a box-like inner shell including side, top, rear and bottom walls defining a cargo receiving chamber;

locating the inner shell within the outer shell;

locating thermal insulation material between the corresponding side, top, rear and bottom walls of the inner and outer shells;

installing a power operated refrigeration system with an evaporator controlling the air within the inner shell and connected to a motor driven compressor and at least one exhaust fan located outside of the outer shell;

locating a plurality of smoke detectors outside of the outer shell for sensing smoke in the ambient air surrounding the cargo container, and

controlling the exhaust fan to shut down in response to smoke detected by any one of the smoke detectors.

38. A method of making a cargo container assembly adapted for transporting a temperature sensitive cargo supported by a pallet, said method comprising the steps of:

forming a box-like outer shell including side, top, rear and bottom walls defining a front opening with a moveable door assembly for closing the opening;

forming a box-like inner shell including side, top, rear and bottom walls defining a cargo receiving chamber;

locating the inner shell within the outer shell;

locating thermal insulation material between the corresponding side, top, rear and bottom walls of the inner and outer shells;

installing a power operated refrigeration system with an evaporator controlling the air within the inner shell and connected to a motor driven compressor and at least one exhaust fan located outside of the outer shell;

locating a plurality of temperature and humidity sensors outside the outer shell for sensing the temperature and humidity of the ambient air surrounding the cargo container, and

controlling the exhaust fan to shut down in response to sensing temperature or humidity outside predetermined ranges by any one of the temperature and humidity sensors.

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